Variable Angle Stair Railing Bracket Hinge

ABSTRACT

A stair railing hinge includes specially adapted leaves that interlock to define a range of motion suitable for all stair railing implementations, and allow for good contact surfaces at every point. The stair railing hinge is compact enough to be completely concealed by a railing cover. A hinge kit includes leaves defining different ranges of motion for a top railing and bottom railing respectively.

FIELD OF THE INVENTION

Embodiments of the inventive concepts disclosed herein are directed generally toward stair railing bracket, and more particularly toward an adjustable angle stair railing bracket hinge.

BACKGROUND

Stair rails may abut a post at a range of possible angles depending on the specifics of the staircase. Existing brackets are not adjustable to account for variations in the angle of contact between the rails and posts; and mass produced brackets generally form a 90° angle which is not useful for any implementation. Leaf and pin hinges allow for adjustability but are generally weak and ill-suited to the stresses of stair rails. Custom fabricated brackets and hinges are stronger, but also more expensive and provide a poor contact surface for all of the necessary connecting components.

Consequently, it would be advantageous if an apparatus existed that is suitable for connecting stair rails to posts in a range of range of angles, and providing good contact surfaces at all of the connecting points.

SUMMARY

In one aspect, embodiments of the inventive concepts disclosed herein are directed to a stair railing hinge with specially adapted leaves that interlock to define a range of motion suitable for all stair railing implementations, and allowing for good contact surfaces at every point. Furthermore, the stair railing hinge is compact enough to be completely concealed by a railing cover.

In a further aspect, a hinge kit includes leaves defining different ranges of motion for a top railing and bottom railing respectively.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and should not restrict the scope of the claims. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate exemplary embodiments of the inventive concepts disclosed herein and together with the general description, serve to explain the principles.

BRIEF DESCRIPTION OF THE DRAWINGS

The numerous advantages of the embodiments of the inventive concepts disclosed herein may be better understood by those skilled in the art by reference to the accompanying figures in which:

FIG. 1 shows a side environmental view of exemplary embodiments of stair railing hinges according to the inventive concepts disclosed herein;

FIG. 2A shows a perspective view of a stair railing hinge according to one embodiment of the inventive concepts disclosed herein;

FIG. 2B shows a side view of a stair railing hinge leaf according to one embodiment of the inventive concepts disclosed herein;

FIG. 2C shows a side view of a stair railing hinge movement according to one embodiment of the inventive concepts disclosed herein;

FIG. 3A shows a perspective view of a stair railing hinge according to one embodiment of the inventive concepts disclosed herein;

FIG. 3B shows a side view of a stair railing hinge leaf according to one embodiment of the inventive concepts disclosed herein;

FIG. 3C shows a side view of a stair railing hinge movement according to one embodiment of the inventive concepts disclosed herein;

FIG. 4 shows a perspective view of a stair railing hinge post leaf according to one embodiment of the inventive concepts disclosed herein;

FIG. 5A shows a perspective environmental view of stair railing hinges according to the inventive concepts disclosed herein in a railing;

FIG. 5B shows a perspective environmental view of stair railing hinges according to the inventive concepts disclosed herein enclosed in a railing;

FIG. 6A shows a perspective, sectional environmental view of a stair railing hinge according to the inventive concepts disclosed herein enclosed in a railing;

FIG. 6B shows a perspective, sectional environmental view of a stair railing hinge according to the inventive concepts disclosed herein enclosed in a railing;

DETAILED DESCRIPTION

Before explaining at least one embodiment of the inventive concepts disclosed herein in detail, it is to be understood that the inventive concepts are not limited in their application to the details of construction and the arrangement of the components or steps or methodologies set forth in the following description or illustrated in the drawings. In the following detailed description of embodiments of the instant inventive concepts, numerous specific details are set forth in order to provide a more thorough understanding of the inventive concepts. However, it will be apparent to one of ordinary skill in the art having the benefit of the instant disclosure that the inventive concepts disclosed herein may be practiced without these specific details. In other instances, well-known features may not be described in detail to avoid unnecessarily complicating the instant disclosure. The inventive concepts disclosed herein are capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.

As used herein a letter following a reference numeral is intended to reference an embodiment of the feature or element that may be similar, but not necessarily identical, to a previously described element or feature bearing the same reference numeral (e.g., 1, 1 a, 1 b). Such shorthand notations are used for purposes of convenience only, and should not be construed to limit the inventive concepts disclosed herein in any way unless expressly stated to the contrary.

Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by anyone of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

In addition, use of the “a” or “an” are employed to describe elements and components of embodiments of the instant inventive concepts. This is done merely for convenience and to give a general sense of the inventive concepts, and “a” and “an” are intended to include one or at least one and the singular also includes the plural unless it is obvious that it is meant otherwise.

Finally, as used herein any reference to “one embodiment,” or “some embodiments” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the inventive concepts disclosed herein. The appearances of the phrase “in some embodiments” in various places in the specification are not necessarily all referring to the same embodiment, and embodiments of the inventive concepts disclosed may include one or more of the features expressly described or inherently present herein, or any combination of sub-combination of two or more such features, along with any other features which may not necessarily be expressly described or inherently present in the instant disclosure.

Broadly, embodiments of the inventive concepts disclosed herein are directed to a specialized leaf hinge for securely attaching stair rails to posts so that the leaf hinge is completely concealed by the stair railing.

Referring to FIG. 1, a side environmental view of exemplary embodiments of stair railing hinges according to the inventive concepts disclosed herein is shown. A stair railing 100 includes a top railing 102 and a bottom railing 104 connected to railing posts 106 via hinges 108, 110 according to exemplary embodiments of the present inventive concepts. In some embodiments, the top railing 102 may be attached to the railing posts 106 via a first hinge type 108 at the high side (top rake) and a second hinge type 110 at the low side (bottom rake). Likewise, the bottom railing 104 is attached to the railing posts 106 via a first hinge type 108 at the high side and a second hinge type 110 at the low side. In other embodiments, hinges 108, 110 may be disposed in other configurations based on the required top rake and bottom rake on the high side and the low side of the railing 102, 104 respectively. Alternatively, hinge 108, 110 placement may be defined by the hardware connecting the hinges 108, 110 to the top railing 102 and bottom railing 104. Hinge types 108, 110 are generally distinguished by absolute and relative ranges of motion as more fully described herein.

In some embodiments, the top railing 102 and bottom railing 104 may include cap elements (not shown) that extend from one railing post 106 to the other railing post 106, and completely conceal the hinges 108, 110.

While FIG. 1 shows posts 106 and railings 102, 104 substantially perpendicular, such representation is merely for clarity in defining various elements. A person skilled in the art may appreciate that the hinges 108, 110 will generally be installed with some amount of deflection (rake) such that the railings 102, 104 will not be at right angles to the posts 106.

Referring to FIG. 2A, a perspective view of a first stair railing hinge type 108 according to one embodiment of the inventive concepts disclosed herein is shown. The first hinge type 108 includes a railing leaf 200 and a post leaf 202. The railing leaf 200 may engage a stiffening element in a top or bottom railing. In some embodiments, the railing leaf 200 is bolted to the stiffening element via one or more stiffener bolt holes 222. The railing leaf 200 may be comprised of a sufficiently thick material to allow the railing leaf 200 to extend beyond the edge of the stiffening element and still provide sufficient mechanical support between the stiffening element and the railing post. In such an embodiment, substantial latitude is provided in the length of the stiffening element to allow for fast installation.

The railing leaf 200 and post leaf interlock and are held together by one or more hinge screws 204. The one or more hinge screws 204 prevent lateral motion between the railing leaf 200 and the post leaf 202; in other embodiments, the one or more hinge screws 204 also cause expansion in the post leaf 202 to create a friction lock between the railing leaf 200 and the post leaf 202.

Referring to FIG. 2B, the railing leaf 200 includes a railing engaging portion 206 that engages a stair railing component such as an aluminum stiffener or any structural member that the railing engaging portion 206 can be screwed or bolted to, and a post leaf engaging portion 208. The post leaf engaging portion 208 comprises a first position stop 210 and a second position stop 212 that define a post leaf rotation channel 214 having a defined range of motion. The post leaf engaging portion 208 may also define a stiffener abutting surface 216 to define a minimum clearance from the railing during installation.

Referring to FIG. 2C, the first position stop 210 and second position stop 212 interact with the post leaf 202 to define a first terminal position 218 for the post leaf 202 and a second terminal position 220 for the post leaf 202. The first terminal position 218 and second terminal position 220 define the outermost deflections of a useful range for using the first hinge type 108 in stair railing installation. The range defined by the first terminal position 218 and the second terminal position 220 may be approximately 40°.

In some embodiments, the post leaf 202 may include one or more recesses for engaging the first position stop 210 and/or the second position stop 212.

In some embodiments, the interface between the railing leaf 200 and the post leaf 202 provides sufficient strength to support the weight of a railing. In some embodiments, one or more hinge screws 204 may create additional tension at the interface to enhance the carrying capacity of the first hinge type 108.

In some embodiments, the railing leaf 200 and post leaf 202 may be extruded rather than stamped.

Referring to FIG. 3A, a perspective view of a second stair railing hinge type 110 according to one embodiment of the inventive concepts disclosed herein is shown. The second hinge type 110 includes a railing leaf 300 and a post leaf 202. The railing leaf 300 may engage a stiffening element in a top or bottom railing. In some embodiments, the railing leaf 300 is bolted to the stiffening element via one or more stiffener bolt holes 322. The railing leaf 300 may be comprised of a sufficiently thick material to allow the railing leaf 300 to extend beyond the edge of the stiffening element and still provide sufficient mechanical support between the stiffening element and the railing post. In such an embodiment, substantial latitude is provided in the length of the stiffening element to allow for fast installation.

The railing leaf 300 and post leaf interlock and are held together by one or more hinge screws 304. The one or more hinge screws 304 prevent lateral motion between the railing leaf 300 and the post leaf 202; in other embodiments, the one or more hinge screws 304 also cause expansion in the post leaf 202 to create a friction lock between the railing leaf 300 and the post leaf 202.

Referring to FIG. 3B, the railing leaf 300 includes a railing engaging portion 306 that engages a stair railing component such as an aluminum stiffener or any structural member that the railing engaging portion 306 can be screwed or bolted to, and a post leaf engaging portion 308. The post leaf engaging portion 308 comprises a first position stop 310 and a second position stop 312 that define a post leaf rotation channel 314 having a defined range of motion. The post leaf engaging portion 308 may also define a stiffener abutting surface 316 to define a minimum clearance from the railing during installation.

Referring to FIG. 3C, the first position stop 310 and second position stop 312 interact with the post leaf 202 to define a first terminal position 318 for the post leaf 202 and a second terminal position 320 for the post leaf 202. The first terminal position 318 and second terminal position 320 define the outermost deflections of a useful range for using the second hinge type 110 in stair railing installation. The range defined by the first terminal position 318 and the second terminal position 320 may be approximately 40°.

In some embodiments, the post leaf 202 may include one or more recesses for engaging the first position stop 310 and/or the second position stop 312.

In some embodiments, the interface between the railing leaf 300 and the post leaf 202 provides sufficient strength to support the weight of a railing. In some embodiments, one or more hinge screws 304 may create additional tension at the interface to enhance the carrying capacity of the second hinge type 110.

The first hinge type 108 and second hinge type 110 generally define different usable ranges of deflection between the railing leafs 200, 300 and post leafs 202. The different ranges of deflection may be useful for different installation purposes. For example, one hinge type 108, 110 may be useful for installations where the attached stiffener is on top of the hinge while the other may be useful when the attached stiffener is beneath the hinge; or, one hinge type 108, 110 may be useful for portions of the installation where the railing is at an obtuse angle to the post while the other hinge type 108, 110 may be useful for portions of the installation where the railing is at an acute angle to the post.

In some embodiments, the railing leaf 300 may be extruded rather than stamped.

Referring to FIG. 4, a perspective view of a stair railing hinge post leaf 220 according to one embodiment of the inventive concepts disclosed herein is shown. In some embodiments, the post leaf 202 defines a first contact surface 400 that abuts a screw head and a second contact surface 402 that abuts a post surface during installation. The first contact surface 400 and second contact surface 402 define an angle that allows an installer to screw the post leaf 202 to a post such that the screws in screw holes 404 defined by the post leaf 202 make full contact with the first contact surface even when the corresponding railing leaf is attached to a railing and is already deflected with respect to the post leaf 202. Furthermore, the shape, and specifically the amount of material comprising the post leaf hinge 202, provides a hinge leaf with sufficient strength to support a stair railing while being short enough to be completely concealed within a railing cap element.

As illustrated in FIGS. 2C and 3C, the shape of the post leaf 202 is such that, even when the post leaf 202 is oriented in one of the terminal positions defined by the corresponding railing leaf, an installer still has access to the screw holes 404 for screwing the post leaf 202 to a post with all of the screws abutting the flat first contact surface 400 of the post leaf, and thereby provide the most secure join possible. By comparison, a flat post leaf at any angle less than 90° to a corresponding railing leaf (which would necessarily be true for some hinges in any conventional stair railing installation) would always be obscured and require the installer to screw the flat post leaf down with screws at an angle so that only a portion of the screw head would be in contact with the flat post leaf.

Furthermore, the post leaf 202 may define a first position stop engaging surface 406 that fully or partially interlocks with a first position stop in a post leaf engaging portion of a railing leaf when the post leaf 202 is in or near a first terminal position. Likewise, the post leaf 202 may define a second position stop engaging surface 408 that engages or abuts a second position stop in a post leaf engaging portion of a railing leaf when the post leaf 202 is in or near a second terminal position. The first position stop engaging surface 406 and second position stop engaging surface 408 may provide additional support when the post leaf 202 is in or near a terminal position, which is a likely state during installation.

In some embodiments, the post leaf 202 includes a railing leaf engaging element 410 that allows the post leaf 202 to pivot with respect to the railing leaf. The railing leaf engaging element 410 may define a hinge screw hole 412. A hinge screw inserted in the hinge screw hole 412 may prevent lateral movement of the post leaf 202 and/or expand the railing leaf engaging element 410 to create a friction lock between the post leaf 202 and the corresponding railing leaf.

Referring to FIGS. 5A and 5B, perspective environmental views of stair railing hinges 108, 110 according to the inventive concepts disclosed herein in a railing 500 is shown. In some embodiments, the railing 500 comprises a stiffener 502 and a railing cap element 504. The stiffener 502 connects to hinges 108, 110, joining two stair railing posts. The railing cap element 504 may comprise polyvinyl chloride (PVC) or other extruded or machined material, or any hollow cap that may fit over the stiffener and hinges 108, 110. During installation, the railing cap element 504 may be cut to a length and contour that conforms to the shape and distance between the stair railing posts, and concealing the hinges 108, 110. In some embodiments, the stiffener 502 may be installed in either a top railing channel or bottom railing channel of a PVC stair railing assembly. Such assembly may comprise a plurality of spindles connecting a U-shaped top rail channel and an inverted U-shaped bottom rail channel; each stiffener 502 is seated in either rail channel and the corresponding railing cap element 504 may snap over the rail channel.

In some embodiments, the stiffener 502 may be connected to a first hinge type 108 and a second hinge type 110 as necessary to conform to the angle between the railing 500 and each stair railing post.

Referring to FIG. 6A, a perspective, sectional environmental view of a first stair railing hinge type 108 according to the inventive concepts disclosed herein enclosed in a railing is shown. The hinge 108 is connected to the stiffener 502 via one or more fasteners 600. The hinge 108 and stiffener 502 may include a plurality of fastener holes such that the hinge 108 may be connected to the stiffener 502 in a position sufficient to bridge any gap between the stiffener 502 and a railing post. During installation, the installer may position the hinge 108 in a channel in the stiffener 502, and then drill one or more holes in the stiffener 502 corresponding to one or more holes in a railing leaf in the hinge 108. The hinge 108 is then connected to a railing post via a plurality of railing post screws 602 in a post leaf of the hinge 108.

Referring to FIG. 6B, a perspective, sectional environmental view of a second stair railing hinge type 110 according to the inventive concepts disclosed herein enclosed in a railing is shown. The hinge 110 is connected to the stiffener 502 via one or more fasteners 600. The hinge 110 and stiffener 502 may include a plurality of fastener holes such that the hinge 110 may be connected to the stiffener 502 in a position sufficient to bridge any gap between the stiffener 502 and a railing post. During installation, the installer may position the hinge 110 in a channel in the stiffener 502, and then drill one or more holes in the stiffener 502 corresponding to one or more holes in a railing leaf in the hinge 110. The hinge 110 is then connected to a railing post via a plurality of railing post screws 602 in a post leaf of the hinge 110.

It is believed that the inventive concepts disclosed herein and many of their attendant advantages will be understood by the foregoing description of embodiments of the inventive concepts disclosed, and it will be apparent that various changes may be made in the form, construction, and arrangement of the components thereof without departing from the broad scope of the inventive concepts disclosed herein or without sacrificing all of their material advantages. The form herein before described being merely an explanatory embodiment thereof, it is the intention of the following claims to encompass and include such changes. 

What is claimed is:
 1. A stair railing hinge apparatus comprising: a railing leaf comprising: a railing engaging portion; and a post leaf engaging portion having a first position stop and a second position stop; a post leaf having a first contact surface and a second contact surface defining one or more screw holes, the first contact surface and second contact surface defining an angle such that a screw inserted through the one or more screw holes abuts the first contact surface while the second contact surface abuts a railing post.
 2. The stair railing hinge apparatus of claim 1, wherein the post leaf defines a first engaging surface configured to engage the first position stop.
 3. The stair railing hinge apparatus of claim 2, wherein the post leaf defines a second engaging surface configured to engage the second position stop.
 4. The stair railing hinge apparatus of claim 1, wherein the first position stop and second position stop define a range of motion of the post leaf.
 5. The stair railing hinge apparatus of claim 4, wherein the range of motion is less than 40°.
 6. The stair railing hinge apparatus of claim 1, wherein the post leaf defines a hinge screw hole.
 7. A railing installation kit comprising: a first stair railing hinge comprising: a railing leaf comprising: a railing engaging portion; and a post leaf engaging portion having a first position stop and a second position stop defining a first range of motion; and a post leaf having a first contact surface and a second contact surface defining one or more screw holes, the first contact surface and second contact surface defining an angle such that a screw inserted through the one or more screw holes abuts the first contact surface while the second contact surface abuts a railing post; and a stiffener element configured to attach to the first stair railing hinge at a proximal end.
 8. The railing installation kit of claim 7, further comprising: a second stair railing hinge comprising: a railing leaf comprising: a railing engaging portion; and a post leaf engaging portion having a first position stop and a second position stop defining a second range of motion; and a post leaf having a first contact surface and a second contact surface defining one or more screw holes, the first contact surface and second contact surface defining an angle such that a screw inserted through the one or more screw holes abuts the first contact surface while the second contact surface abuts a railing post, wherein the stiffener element is further configured to attach to the second stair railing hinge at a distal end.
 9. The railing installation kit of claim 8, wherein the first range of motion is distinct from the second range of motion.
 10. The railing installation kit of claim 8, wherein the first stair railing hinge is configured for installation between the stiffener element and a railing post where an angle defined by the stiffener element and the railing post is obtuse as measured from the first stair railing hinge.
 11. The railing installation kit of claim 8, wherein the second stair railing hinge is configured for installation between the stiffener element and a railing post where an angle defined by the stiffener element and the railing post is acute as measured from the first stair railing hinge.
 12. The railing installation kit of claim 7, further comprising a railing cap element configured to cover the stiffener element.
 13. The railing installation kit of claim 9, wherein the railing cap element is further configured to conceal the first stair railing hinge when installed.
 14. A stair railing comprising: a first stair railing hinge comprising: a railing leaf comprising: a railing engaging portion; and a post leaf engaging portion having a first position stop and a second position stop defining a first range of motion; and a post leaf having a first contact surface and a second contact surface defining one or more screw holes, the post leaf affixed to a first railing post via one or more screws, each of the one or more screws abutting the first contact surface, and the second contact surface abutting the first railing post; and a stiffener element attached to the first stair railing hinge at a proximal end.
 15. The stair railing of claim 14, further comprising: a second stair railing hinge comprising: a railing leaf comprising: a railing engaging portion; and a post leaf engaging portion having a first position stop and a second position stop defining a second range of motion; and a post leaf having a first contact surface and a second contact surface defining one or more screw holes, the post leaf affixed to a second railing post via one or more screws, each of the one or more screws abutting the first contact surface, and the second contact surface abutting the second railing post, wherein the stiffener element is attached to the second stair railing hinge at a distal end.
 16. The stair railing of claim 15, wherein the first range of motion is distinct from the second range of motion.
 17. The stair railing of claim 16, wherein the first stair railing hinge is disposed between the stiffener element and the first railing post at an obtuse angle as measured from the first stair railing hinge.
 18. The stair railing of claim 17, wherein the second stair railing hinge is disposed between the stiffener element and the second railing post at an acute angle as measured from the first stair railing hinge.
 19. The stair railing of claim 18, further comprising a railing cap element covering the stiffener element.
 20. The stair railing of claim 19, wherein the railing cap element conceals the first stair railing hinge when installed. 